Prestige TSG
Prestige TSG
Prestige TSG
Solo 110
Water Boiler
2004-28 TSG-SOLO-9/04
Table of Content
INTRODUCTION
Page 1
Page 3
Page 5
Page 8
Page 9
Page 14
COMBUSTION TEST/SETTINGS
Page 20
Page 22
REPLACEMENT PART
Page 23
NOTICE
Indicates special instructions on installation, operation or maintenance, which are important to the equipment/product, but not related to personal injury hazards.
WARNING
This guide is to be used in conjunction with the PRESTIGE Installation and Maintenance manual. Procedures and servicing listed in this manual must be performed by a qualified service technician, installer, service agency or gas supplier. Any procedures or service performed by an unqualified individual or service agency can result in severe personal injury, death or substantial property damage.
Introduction Introduction
This guide is to be used in conjunction with the Triangle Tube PRESTIGE Boiler Installation and Maintenance Manual.
Review all appropriate manuals before leaving for the job site At the job site: Clarify problem Have the PRESTIGE manual and any other wiring, zone control or piping diagrams, or installation guides readily available.
REMEMBER
Follow the Troubleshooting Guide step by step, always double checking your results. Skipping steps or not completing steps can lead to wrong conclusions, repeated visits to the job site, unhappy customers and unnecessary warranty claims.
WARNING
Never bypass (jumper) any boiler control or device except for momentary testing when troubleshooting the boiler as outlined in this guide, severe personal injury, death or substantial property damage can result.
WARNING
Do not bypass any fuse with a jumper. Do not replace any fuse with a fuse that is not specified. Failure to comply could result in severe personal injury, death or substantial property damage. 7. Re-install the control module cover and the front jacket panel when completed.
WARNING
After completing any servicing of the boiler verify proper operation of the boiler. Steps to verify proper operation are outlined in the Start-Up Preparation in the PRESTIGE Installation manual. Failure to comply could result in severe personal injury, death or substantial property damage.
Control Module
F1 Fuse 5 - AMP Fast Acting 120V-High Voltage
StbY
Display
Boiler function STANDBY, no demand for heat Fan prepurge (10 seconds) or post purge cycle Ignition sequence Burner ON for space heating (CH) Burner ON for domestic water heating (DHW) Pre-check for air flow prior to prepurge cycle Burner OFF due to reaching temperature set point Post pump cycle for primary space heating (1 minute) Post pump cycle for domestic hot water (30 seconds) Burner blocked: Supply temperature too high (203 F) .Burner will remain OFF until outlet temperature drops below 200 F Return temperature too high (203 F). Burner will remain OFF until temperature drops below 200 F Return temperature is measured higher than supply temperature. Burner will remain OFF until corrected. Supply temperature increased too quickly. Burner will remain OFF for a 10 minute period. Burner will recycle, increasing waiting period 1 minute for a max. 15 minutes Factory supplied LWCO pressure device or external limit (terminals 15 & 16) is OPEN. Burner off for 150 seconds, auto reset. No blower signal Blower signal present, Burner will remain OFF until condition terminates Temperature rise between the supply and return is more than 72 F. Burner will remain OFF for 150 seconds. Burner will recycle increasing wating period 1 minute for a max. 20 cycle. Short circuit measured across flue temperature sensor terminals. Burner OFF until corrected. Open circuit measured across the flue temperature sensors. Flue temperature greater than 241 F less than 250 F. Burner off for 150 seconds Wait for the blower to start
After the boiler is turned on, the control panel will display STANDBY mode as shown in the figure above. This is the standard mode for the PRESTIGE. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display. Any parameters that were modified are then enabled. The first character shows (on the left side of the display) the current status of the boiler depending on the condition of both the boiler and the burner. The last 3 characters indicate the start temperature. See page 8 for additional information. If the burner is blocked due to a soft lockout, the display alternates between a 9 followed by the boiler outlet temperature and b with a two digit error code. See page 9 12 for detailed information on the corrective and preventive actions for the soft lockouts.
0 180 1 180 2 180 3 180 4 180 5 180 6 180 7 180 8 180 9 180 b 18 b 19
Display
Boiler function Internal check Test function: Burner on, high fire mode Test function: Burner on, low fire mode
b 24 b 25 b 26
TO TEMPORARY PLACE THE BURNER INTO HIGH FIRE MODE: press the MODE button with + button simultaneously. TO TEMPORARY PLACE THE BURNER INTO LOW FIRE MODE: press the MODE button with - button simultaneously.
b 28 b 29 b 30 b b b b 35 40 52 65
NOTICE
The control module will maintain the fixed firing rate for approximately 10 minutes before defaulting to normal operating conditions. Press the + and - button simultaneously to deactivate the high or low fire mode.
P ARA
Information Mode
I NFO
To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once. To scroll through the list of parameters, simply press the STEP button. To modify a parameter value, use the + or - keys. Then press STORE to save the value you just changed. The display flashes once to confirm the data has been saved. To activate the parameters you changed, press MODE once more (which brings you into the INFORMATION mode). However, if you do not press a key, the system returns to STANDBY mode after 20 minutes and automatically enables the changes.
Key:
MODE
To switch from STANDBY mode to INFORMATION mode, press MODE twice. Press STEP until the system displays the information you need. The point located behind the first position flashes to indicate that the boiler is in INFO mode.
Key:
MODE
Display
MODE
P ARA I NFO
Display
Display
P ARA
Screen
STEP
Key:
STEP
Description of parameters
STEP
STEP
STEP
1. . 150 2. 01 3. 01 4.1 8 0
Space Heating Mode (See Note 2) Maximum temperature in space heating (CH) mode. In applications using an outdoor sensor, this is the boiler outlet target temperature at an outdoor temperature of 0 F
STEP
STEP
STEP
STEP
STEP
1. 180 21 60 3. 18 4. 55 5. 50 1 6. 180 7. 1 8. 1 9. 32
Description of parameters Measured outlet (supply) water temperature Measured inlet (return) water temperature This parameter is not used Measured outdoor temperature (Optional outdoor sensor required) Measured flue temperature Calculated (target) outlet water temperature Rate of increase in the outlet water temperature F/sec Rate of increase in the return water temperature F/sec This parameter is not used
Note 1: This parameter should not be changed from the factory setting. The performance of the DHW will be affected and can become unreliable. Note 2: This parameter should not be changed from the factory setting. The performance of the CH (central/space heating) will be affected and can become unreliable.
E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E
00 02 03 04 05 06 07 08 09 11 12 13 14 15 16 17 18 19 25 28 29 31 32 36 37 44 52 60 61 65
Boiler display shows a 0 for the first digit on the left followed by 2 or 3 digits (boiler temperature)
Check to see if room and DHW thermostats are satisfied. If the thermostats are satisfied the boiler is off due to no call for heat. Turn up a thermostat and the boiler should begin ignition sequence. If the room thermostat or DHW thermostat is calling for heat and the boiler is not firing and the boiler is below the maximum operating temperature. Check for 24 volts across the control module internal fuse F3, which is located toward the middle of the control and positioned vertically see Fig. 1 page 4. If necessary replace the fuse. See Serving Tips and Instructions, page 3, for accessing the internal fuses of the control module. Check and verify Parameters 2 and 3 are correct as outlined on page 6. Both parameters should be set as 01, which turns DHW and CH modes ON. Temporarily jump low voltage terminals 7 and 8 on the 24V terminal strip. If boiler operates check the room thermostat wiring and thermostat control. Replace as needed. Remove jumper when completed. Temporarily jump low voltage terminals 11 and 12 on the 24V terminal strip. If boiler operates check the DHW thermostat wiring and thermostat control. Replace as needed. Remove jumper when completed. Disconnect power to the boiler. Check all wiring and wiring connections and compare to the wiring diagram. Ensure all wiring and wiring connection are in good condition and secure. If necessary, replace complete wiring harness. If all the above steps fail to resolve the problem, replace the control module.
Boiler display shows a number of 1 to 8 for the first digit on the left followed by 2 or 3 digits (boiler temperature)
The boiler is in normal operating mode. Reference the boiler installation manual for detailed explanation of the boiler operation.
b- 19
If the primary boiler return water temperature exceeds 203F, the burner will
shut down until both the supply and return temperature drops 9F below the original set point temperature. The boiler circulator will continue operating. This problem rarely occurs unless the boiler experiences an Error Code 18 and the system is charged with a water temperature in excess of 203F - Verify the boiler and heating system are filled with water and the LWCO is operating properly. - Ensure the boiler and heating system have been properly purged and there is no entrapped air. - Inspect and verify heating system piping and its components. Ensure piping is per the recommendations given in the Prestige Installation Manual or per other approved/recognized designed configurations. - Ensure the boiler piping is correct and the water flow is not reversed or pipes are cross connected. Use a temperature-metering device to measure the return water temperature entering the boiler. Compare this measured temperature with the display temperature (INFO Mode display, 2 is the first digit on the left followed by the temperature.) - Replace the return temperature sensor if the temperature comparison is largely varied. - Replace the control module if the sensor replacement does not resolve the problem.
9
b- 25
If the primary boiler supply water temperature rate of increase is deemed too quick, the burner will shut down for a 10 minute period. If the condition is not corrected during the next cycle, the burner shut down period of 10 minutes will increase an additional minute. The boiler will continue for 5 cycles until a hard lockout will occur. This problem will occur if the flow rate on the boiler is too low. Check for the following conditions: - Verify the boiler and heating system are filled with water and the LWCO is operating properly. - Ensure the boiler and heating system have been properly purged and there is no entrapped air. - Inspect and verify heating system piping and its components. Ensure piping is per the recommendations given in the Installation Manual or per other approved/recognized designed configurations. Verify and ensure the boiler space heating CH circulator is operating properly. - Check and verify 120V at the circulator wiring in the circulator junction box. If no voltage is measured, check circulator wiring and connections. - Check and verify 120V at the MCBA control module along terminals X1-4 and X1-3. If no voltage is measured, replace control
10
b- 26
LWCO Device
If the LWCO device is determined to be open by the control module the boiler will remain in a shut down mode until the condition is corrected. Once the condition is corrected the boiler will remain in the shut down mode for an additional 150 seconds before startup. - Check the pressure gauge on the boiler and ensure the system is at minimum 10 psig. - Ensure proper operation of the boiler make up system and fill valve. Check continuity across the LWCO terminals for closed contacts if the boiler system pressure gauge reads 10 psig or greater. - Replace the LWCO device if the continuity shows an open circuit and the system pressure is 10 psig or greater. - Check the wiring and contacts from the LWCO to the control module terminals if the continuity check shows a close circuit. Replace the low voltage wiring harness if needed. - Replace control module if the replacement of the wiring harness does not resolve the problem.
b- 28
Blower Assembly
Will occur if during the ignition sequence the blower does not start. The boiler display will indicate a status code of 5 during the ignition sequence. Disconnect the connector at the blower. Restart the boiler sequence and check for 35Vdc at the connector between the black and white wires (pin 1 & 5). - If 35Vdc is not present at the connector, inspect the wiring harness and replace if necessary. Replace the control module if wire harness replacement does not resolve the problem. -- If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure a secure connection. Replace the blower assembly if problem is not resolved.
b- 29
Blower Assembly
The control module is detecting the blower in operation when it should not be. Check and verify the wiring from the blower to the control module is correct as shown in the appliance wiring schematic, page 22. - Replace the wiring harness from the control module to the blower. Replace the blower if the replacement of the wiring harness does not resolve the problem. Replace control module if blower replacement does not resolve the problem.
11
b- 35
The control module detects a short or jumped out condition of the flue temperature sensor. This code will also appear briefly prior to a hard lockout if the flue gas temperature exceeds 250F. The burner will remain off until the condition is corrected. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module.
12
b- 52
The control module detects the flue temperature greater than 241F, less than 250F. Burner off for 150 seconds. This is an indication the heat exchanger flue ways may need cleaning. Reference the Maintenance section of the installation manual for procedures on cleaning the flue side of the heat exchanger. Isolate the boiler from the boiler system piping and drain the boiler heat exchanger. Flush the boiler heat exchanger several times, checking the discharge water for signs of scale or sediment. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module.
b- 65
Blower Assembly
The control module does not detect proper blower operation during a call for heat. Disconnect the 35Vdc connector at the blower. Restart the boiler sequence and check for 35Vdc at the connector between the black and white wires (pin 1 & 5). - If 135Vdc is not present at the connector, inspect the wiring harness and replace if necessary. Replace the control module if the wire harness replacement does not resolve the problem. - If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure a secure connection. Replace the blower assembly if problem is not resolved.
13
E- 02
This error will occur if the boiler has failed to establish flame detection during the ignition sequence. The lockout will occur after 5 tries. If no ignition spark occurs during the ignition sequence: - Check the ignition electrode cable, the electrode boot connector and all connections, ensure all are in good condition. Replace if damaged. - Inspect the insulation of the electrode cable and the electrode igniter; ensure there is no damage. Replace as needed. - Check the ground lead for a secure connection from the control module ground to the burner mounting plate. Use a ground continuity check to verify a good ground. If there is an ignition spark during the ignition sequence, but no flame: - Verify the manual shutoff valve on the gas supply piping is in the OPEN position. - Check and verify the gas pressure at the inlet of the valve during ignition sequence. Ensure the gas pressure maintains a minimum 5 inches w.c during ignition sequence. Note: All gas appliances within the building should be operating during this measurement. - Check and verify all gas piping is free of obstructions and has been purged of all air. - Check the gas meter for indications of gas flow during the ignition sequence. - Remove the ignition electrode to inspect for damage. Clean any white oxides off the electrode if necessary. Replace the electrode if damaged or will not clean. - Replace the gas valve rectifier cable. - Remove and inspect the gas valve and venturi gas ports. Ensure ports are free of obstructions.
14
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the rectifier cable. E- 04 Loss of Power This error will occur if power to the boiler is lost after a lockout has occurred. The boiler must be manually reset and the original lockout code will be lost. This error will also occur if the service technician tries to reset a hard lockout by turning the boiler OFF and then ON as an attempt to reset the boiler.
E- 05
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 06
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 07
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 08
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 09
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
15
E- 12
E- 13
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 14
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 15
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 16
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 17
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 18
This error will occur if the boiler supply water temperature exceeds 212F. The following items should be checked:. - Verify the boiler and heating system are filled with water and the LWCO is operating properly. - Ensure the boiler and heating system have been properly purged and there is no entrapped air. - Inspect and verify heating system piping and its components. Ensure piping is per the recommendations given in the Installation Manual or per other approved/recognized designed configurations. Use a temperature-metering device to measure the supply water temperature leaving the boiler. Compare this measured temperature with the display temperature (INFO Mode display, 1 is the first digit followed by the temperature.) - Replace the supply temperature sensor if the temperature comparison is largely varied. - Replace the control module if the sensor replacement does not resolve the problem.
16
This problem rarely occurs unless the boiler experiences an Error Code 18 and the system is charged with a water temperature in excess of 212F. The following items should be checked: - Verify the boiler and heating system are filled with water and the LWCO is operating properly. - Ensure the boiler and heating system have been properly purged and there is no entrapped air. - Inspect and verify heating system piping and its components. Ensure piping is per the recommendations given in the Installation Manual or per other approved/recognized designed configurations. - Ensure the boiler piping is correct and the water flow is not reversed or pipes are cross-connected. Use a temperature-metering device to measure the return water temperature leaving the boiler. Compare this measured temperature with the display temperature (INFO Mode display, 2 is the first digit followed by the temperature.) - Replace the return temperature sensor if the temperature comparison is largely varied. - Replace the control module if the sensor replacement does not resolve the problem.
E- 25
This error will occur if the boiler supply water temperature rate of increase is deemed too rapid. The control module will display a soft lockout of b_25 and initiate a recycle sequence. After 5 cycles the boiler will go into a hard lockout. This problem will occur if the flow rate and demand load on the boiler are too low. Check for the following conditions: - Verify the boiler and heating system are filled with water and the LWCO is operating properly. - Ensure the boiler and heating system have been properly purged and there is no entrapped air. - Inspect and verify heating system piping and its components. Ensure piping is per the recommendations given in the Installation Manual or per other approved/recognized designed configurations. Verify and ensure the boiler central heating CH circulator is operating properly. - Check and verify 120V at the circulator wiring in the circulator junction box. If no voltage is measured, check circulator wiring and connections. - Check and verify 120V at the MCBA control module along terminals X1-4 and X1-3. If no voltage is measured, replace control module. Check circulator wire harness and replace if needed if voltage is measured at the control module. Verify and ensure the external DHW circulator is operating properly. - Check and verify 120V at the circulator wiring in the circulator junction box. If no voltage is measured, check circulator wiring and connections. - Check and verify 120V at the 120V terminal strip between terminals 4 and 5 inside the boiler enclosure. Check circulator wire harness and replace if needed, if voltage is measured at the control module.
17
E- 29
Blower Assembly
The control module is detecting the blower in operation when it should not be. Check and verify the wiring from the blower to the control module is correct as shown in the appliance wiring schematic, page 22. - Replace the wiring harness from the control module to the blower. Replace the blower if the replacement of the wiring harness does not resolve the problem. Replace control module if blower replacement does not resolve the problem.
E- 31
The control module detects a short or jumped out condition of the boiler supply (outlet) temperature sensor. Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module.
E- 32
The control module detects a short or jumped out condition of the boiler return (inlet) temperature sensor. Inspect the boiler return temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module.
E- 36
The control module detects the boiler supply (outlet) temperature sensor as an open circuit. Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module.
18
E- 44
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module. The control module detects the flue temperature exceeding the 250F limitation of the boiler. This is an indication the heat exchanger flue ways may need cleaning. Reference the Maintenance section of the installation manual for procedures on cleaning the flue side of the heat exchanger. Isolate the boiler from the boiler system piping and drain the boiler heat exchanger. Flush the boiler heat exchanger several times, checking the discharge water for signs of scale or sediment. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition, replace as needed. - Replace the sensor and wiring if problem persists. If replacement of sensor and wiring does not resolve the problem, replace the control module. Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module.
E- 52
E- 60
Internal Failure
E- 61
Internal Failure
Reset the boiler control module and retry ignition sequence and boiler operation. If problem continues, replace the control module. The control module does not detect proper blower operation during a call for heat. Disconnect the 35V dc connector at the blower. Restart the boiler sequence and check for 35Vdc at the connector between the black and white wires (pin 1 & 5). - If 35Vdc is not present at the connector, inspect the wiring harness and replace if necessary. Replace the control module if the wire harness replacement does not resolve the problem. - If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure a secure connection. Replace the blower assembly if problem is not resolved.
E- 65
Blower Assembly
19
WARNING
The installation and startup of the PRESTIGE should be performed by a qualified installer / service technician. The startup procedures should include a complete combustion test. The complete combustion test must also be performed after any adjustments to the factory settings on the burner. Failure to comply with these requirements can result in severe personal injury, death or substantial property damage.
Combustion Parameters O2 Min O2 Max. CO2 Min CO2 Max Natural Gas 2.30% 5.30% 8.80% 10.50% Propane 2.70% 4.70% 10.70% 12.00%
20
WARNING
Adjusting the throttle screw clockwise (inward) decreases the volume of gas injected into the burner. Adjustments beyond 2 full turns clockwise will greatly affect the operation of the burner and result in unstable combustion conditions.
WARNING
DO NOT adjust the throttle screw counter-clockwise beyond the initial factory set point. Adjustments counterclockwise beyond the factory set point will increase the volume of gas injected into the burner, resulting in possible unstable combustion conditions and potential dangerous levels of CO.
21
Internal Wiring
Note:
- If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type T wire or its equivalent.
BK W G BL R O V Y BR
22
1 2 3 4 5 6
Incoming Supply L Incoming Supply N Incoming Supply G DHW Circulator L DHW Circulator N DHW Circulator G
7 8 9 10 11 12 13 14 15 16 17 18 19
Thermostat (T-T) Thermostat (T-T) Outdoor Sensor Outdoor Sensor DHW Thermostat DHW Thermostat External Limit - Manual Reset External Limit - Manual Reset External Limit - Auto Reset External Limit - Auto Reset 0-10v Input Controller 0-10v Input Controller Flame Signal
Replacement Parts
9 8
11
10
Description Display/Control Panel Display Back Panel Connection Flange Panel Base Panel Front Jacket Panel Rear Jacket Panel Side Jacket Panel (Left and Right) Top Jacket Panel - Front Top Jacket Panel - Rear Control Cover Panel Wall Mounting Bracket with Hardware
23
Replacement Parts
10 1
11 4 4 5 8
7 6
24
Replacement Parts
8 5 9 4
25
Replacement Parts
Item 1 2 3 4
Description Prestige Control Module Transformer with Surge Protection Prestige Control Module Display Pressure Gauge - Not shown
26
Notes
For additional Technical Assistance Contact: Triangle Tube Engineering Department Tel: (856) 228-8881 Fax: (856) 228-3584 E-mail: [email protected]
27
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